Td420ve Tad733ge - Alternador e Motor de Partida

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Workshop Manual

(Group 23) EDC 4

TD420VE, TAD420VE, TD520GE, TAD520GE, TD520VE

TAD520VE, TAD530/531/532GE, TAD620VE, TD720GE

TAD720GE, TD720VE, TAD720VE , TAD721GE, TAD721VE,

TAD722GE, TAD722VE, TAD730/731/732/733GE


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Contents

Safety information ................................................. 2

Introduction .......................................................... 2

General information .............................................. 5

About the workshop manual ................................. 5

Spare parts .......................................................... 5

Certified engines .................................................. 5

Repair instructions ................................................ 6

Our common responsibility ................................... 6

Tightening torque ................................................. 6

Torque-angle tightening ........................................ 7Lock nuts ............................................................. 7

Strength classes .................................................. 7

Sealants .............................................................. 7

Engine signs ......................................................... 8

Location of engine signs ...................................... 8

Special tools ......................................................... 9

Technical data..................................................... 10

Design and function ............................................ 13

System description, EDC 4 ................................ 13

Other functions .................................................. 14

Component description ...................................... 16

Component location ........................................... 20

Limit values ......................................................... 21

Parameter setting ................................................ 22

Adjustable parameters ....................................... 22Read-only parameters ........................................ 24

Fine adjustment, engine speed regulator ............ 24

Repair instructions .............................................. 26

Working on the EDC4 ......................................... 26Control unit, change ........................................... 27

Speed regulator, change .................................... 27

Starting with auxiliary batteries .......................... 28

Function check.................................................... 29

Diagnostic function with program for PC ............ 29

Fault tracing ........................................................ 30

Symptoms and possible causes ........................ 30

Diagnostic function ............................................. 31

Diagnostic function, tasks .................................. 31

Malfunction message ......................................... 31

Fault tracing guide ............................................. 31

Effect on engine ................................................. 31

Operation ........................................................... 31

Fault codes .......................................................... 33

Electrical fault finding ........................................ 39

General .............................................................. 39

Function checking of cables and connectors ...... 39

Fault tracing of cables and connectors ............... 40

Joining electrical cables for multi-connector ....... 41

Inspection/fault tracing of components ............... 42

Fault tracing the starter motor ............................ 45

Fault tracing the alternator ................................. 46

Electrical system ................................................. 53

Important information about electrical system .... 53

Wiring diagram ................................................... 54

Workshop manual

EDC 4

TD420VE, TAD420VE, TD520GE, TAD520GE, TD520VE

TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VETAD660VE, TD720GE TAD720GE, TD720VE, TAD720VE

TAD721GE, TAD721VE, TAD722GE, TAD722VE,

TAD730/731/732/733GE, TAD750VE, TAD760VE


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Group 23 EDC 4 Safety information

Safety information

Introduction

The workshop manual contains descriptions and repair

instructions for products or product versions noted inthe table of contents, supplied by Volvo Penta. Make

sure that you use the correct workshop literature.

Read the available safety information, General

Infor-

mationand RepairInstructionsin the workshop

manual before you start to do any service work.

Important

The following special warning signs are used in the

workshop manual and on the engine.

WARNING! Warns for the risk of personal injury,major damage to product or property, or seriousmalfunctions if the instruction is ignored.

IMPORTANT! Is used to call attention to thingswhich could cause damage or malfunctions toproduct or property.

NOTE! Is used to call attention to important informa-

tion, to facilitate work processes or operation.

To give you a perspective on the risks which always

need to be observed and precautions which always

have to be taken, we have noted them below.

Make it impossible to start the engine by cuttingsystem current with the main switch(es) andlock it (them) in the off position before startingservice work. Fix a warning sign by the controlstation.

All service work should normally be done on astationary engine. Some work, such as adjust-ments, need the engine to be running, however.Going close to a running engine is a safety risk.

Remember that loose clothes, long hair etc. cancatch on rotating components and cause severeinjury.

If work is done adjacent to a running engine, acareless movement or a dropped tool can leadto personal injury in the worst case. Be carefulwith hot surfaces (exhaust pipes, turbos, chargeair pipes, starting heaters etc.) and hot fluids inpipes and hoses on an engine which is runningor which has just stopped. Re- install all guardswhich have been removed during service work,before re- starting the engine.

Make sure that the warning or information labelson the product are always clearly visible. Re-place labels which have been damaged or paint-ed over.

Never start an engine without the air filter inplace. The rotating compressor turbine in theturbocharger can cause severe injury. Foreignbodies in the inlet pipe can also cause severemechanical damage.

Never use start spray or similar products as astarting aid. Explosions could occur in the inletmanifold. Danger of personal injury.

Only start the engine in a well- ventilated area.

When operated in a confined space, exhaustfumes and crankcase gases must be ventilatedfrom the engine bay or workshop area.

Avoid opening the coolant filling cap when theengine is hot. Steam or hot coolant can sprayout at the same time as the pressure which hasbuilt up is lost. Open the filler cap carefully ifnecessary, and release the excess pressure inthe cooling system. Be extremely careful if atap, plug or coolant hose has to be removedfrom a hot engine. Steam or hot coolant can

stream out in an unexpected direction.

Hot oil can cause burns. Avoid skin contact withhot oil. Make sure that the lubrication oil systemis de- pressurized before doing any work on it.Never start or run the engine with the oil fillercap removed, because of the risk of oil spillage.

Stop the engine before doing any work on thecooling system.


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If other equipment connected to the engine hasaltered its centre of gravity, special lifting devis-es may be needed to obtain the correct balanceand safe handling.

Never do any work on an engine which justhangs from a lifting devise.

Never work alone when heavy components areto be dismantled, even when safe lifting devisessuch as lockable blocks & tackle are used.Even when lifting devises are used, two peopleare needed in most cases. One who operatesthe lifting devise and other who makes sure thatcomponents move freely and are not damagedduring lifting.

Always make sure that there is enough spacefor disassembly where you are working, with no

risk for personal or material damage.

WARNING! Components in the electrical andfuel systems on Volvo Penta products havebeen designed to minimize the risks of explo-sion and fire. The engine must not be operatedin environments with adjacent explosive media.

Only use the fuels recommended by Volvo Pen-ta. Please refer to the instruction book. The useof fuel of inferior quality can damage the engine.In a diesel engine, poor fuel can make the en-gine over- rev, entailing a strong risk of personal

injury and machinery damage. Poor fuel canalso lead to higher maintenance costs.

Remember the following when washing with ahigh pressure washer: Never aim the water jet atseals, rubber hoses, electrical components orthe radiator.

Always use goggles when doing any work wherethere is any risk of splinters, grinding sparks,acid splash or other chemicals. Your eyes areextremely sensitive, injury could cause blind-

ness!

Avoid skin contact with oil! Long- term or repeat-ed skin contact with oil can injure your skin. Theconsequence is irritation, dry skin, eczema andother skin disorders. Used oil is more hazardousto health than new oil. Use protective glovesand avoid oil-soaked clothes and rags. Washregularly, especially before meals. Use specialskin cream to avoid drying and facilitate skincleaning.

Most chemicals intended for the product, suchas engine and transmission oils, glycol, petrol(gasoline) and diesel oil, or chemicals for work-shop use, such as degreasers, paints and sol-vents are hazardous. Read the instruction onthe packages carefully! Always observe thesafety advice, e.g. use of breathing protection,

goggles, gloves etc. Make sure that other per-sonnel are not inadvertently exposed to hazard-ous substances, such as via the air theybreathe. Ensure good ventilation. Handle usedand surplus chemicals in the prescribed manner.

Be very careful when searching for leaks in thefuel system and testing fuel injectors. Use gog-gles. The jet which comes from a fuel injectorhas very high pressure and considerable pene-tration ability. Fuel can force its way deep intobody tissue and cause severe injury. Risk ofblood poisoning (septicemia).

All fuels, and many chemicals, are flammable.Make sure that open flames or sparks can notset them alight. Petrol (gasoline), some thinnersand hydrogen gas from batteries are extremelyflammable and explosive when mixed with air inthe correct ratio. Do not smoke! Provide goodventilation and take the necessary precautionsbefore you start welding or grinding work in thevicinity. Always have a fire extinguisher easilyavailable near the workplace.

Make sure that oil and fuel soaked rags, andused fuel and oil filters are disposed of in a safemanner. Oil soaked rags can self-ignite in cer-tain circumstances. Used fuel and oil filters arepolluting waste and must be handed to an ap-proved waste management facility for destruc-tion, together with used lubrication oil, contami-nated fuel, paint residue, solvents, degreasersand wash residue.

Batteries must never be exposed to openflames or electric sparks. Do not smoke close

to the batteries. The batteries generate hydro-gen gas when charged, which forms an explo-sive gas when mixed with air. This gas is veryflammable and highly explosive. A spark, whichcan be formed if the batteries are wrongly con-nected, is enough to make a battery explodeand cause damage. Do not move the connec-tions when you attempt to start the engine (riskof arcing), and do not stand and lean over one ofthe batteries.


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Never mix up the battery positive and negativepoles when the batteries are installed. If the bat-teries are wrongly connected, this can cause se-vere damage to the electrical equipment. Pleasecheck the wiring diagram!

Always use goggles when charging and handlingbatteries. Battery electrolyte contains highly cor-rosive sulfuric acid. If this comes into contactwith your skin, wash at once with soap and a lotof water. If you get battery acid in your eyes,flush at once with a lot of cold water, and getmedical assistance at once.

Stop the engine and cut the system current withthe main switch(es) before doing any work onthe electrical system.

The clutch must be adjusted with the engineshut off.

The existing lugs on the engine should be usedfor lifting the engine/gearbox etc. Always checkthat the lifting devices are in good condition andthat they have the correct capacity for the lift

(the weight of the engine plus the gearbox andextra equipment if installed).

The engine should be lifted with a customized oradjustable lifting boom for safe handling and toavoid damaging components on top of the en-gine. All chains or cables must be parallel toeach other and should be as square as possibleto the top of the engine.


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Group 23 EDC 4 General information

General information

About the workshop manual

This workshop manual contains descriptions and re-pair instructions for the standard versions of following

engines: TD420VE, TAD420VE, TD520GE,

TAD520GE, TD520VE TAD520VE, TAD530/531/

532GE, TAD620VE, TAD650VE TAD660VE,

TD720GE TAD720GE, TD720VE, TAD720VE

TAD721GE, TAD721VE, TAD722GE, TAD722VE,

TAD730/731/732/733GE, TAD750VE, TAD760VE.

The workshop manual can illustrate tasks done on

any of the engines noted above. This means that the

illustrations and photographs which clarify certain de-

tails might not entirely correspond. The repair meth-

ods are similar in all important respects, however. The

engine designation and number are noted on the type

plate. Please refer to the Engine signs chapter.

The engine designation and number must always be

given in all correspondence about an engine.

The workshop manual has been primarily prepared for

Volvo Penta service workshops and their qualified per-

sonnel. This assumes that people who use the

manual have basic skills and can do the tasks of a

mechanical or electrical nature associated with the

trade.

Volvo Penta constantly improves its products, so we

reserve the right to make modifications without prior

notification. All information in this manual is based on

product data which was available up to the date on

which the manual was printed. Any material changes

introduced into the product or service methods after

this date are notified by means of Service Bulletins.

Spare parts

Spare parts for electrical and fuel systems are subjectto various national safety requirements. Volvo Penta

Original Spares comply with these requirements. No

damage whatever, occasioned by use of non-original

Volvo Penta spares for the product, will be compen-

sated by the warranty offered by Volvo Penta.

Certified engines

The manufacturer certifies that both new engines andthose in use, which are certified for national or re-

gional legislation, comply with the environmental re-

quirements Each product must correspond with the

unit used for certification. The following requirements

for service and spare parts must be complied with, for

Volvo Penta as a manufacturer to be responsible for

ensuring that engines in use comply with the stipu-

lated environmental requirements:

Maintenance and service intervals recommendedby Volvo Penta must be complied with.

Only Volvo Penta Original Spares, intended forthe certified engine variant, may be used.

Service which includes injection pumps, pumpsettings or unit injectors must always be done byan authorized Volvo Penta workshop.

The engine must not be converted or modified inany way, except for the accessories and service

kits which Volvo Penta has approved for the en-gine.

Installation changes to the exhaust pipe and theengine bay air inlet ducts (ventilation ducts) mustnot be done without further discussion, since thiscould affect exhaust emissions. No seals may bebroken by unauthorized personnel.

IMPORTANT! When spare parts are needed,use only Volvo Penta Original Spares.

The use of non-original spares means thatVolvo Penta ceases to be responsible for en-suring that the engine corresponds with thecertified version.

Damage, injury and/or costs of whatever nature,which arise due to the use of non-original VolvoPenta spares for the product in question will notbe compensated by Volvo Penta.


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Group 23 EDC 4 Repair instructions

Repair instructions

The work methods described in the workshop manual

apply to work in a workshop environment. For this rea-

son, the engine is lifted out and mounted on an engine

support. Renovation work which does not need the en-gine to be lifted out can be done in situ, with the same

work methods, unless otherwise specified.

Please refer to the Safety information chapter, where

the meaning of the warning signs used in the Work-

shop Manual are explained in detail.

WARNING!

IMPORTANT!

NOTE!

are not comprehensive in any way, since we can notof course foresee everything, because service work isdone in highly varying circumstances. For this reason,all we can do is to point out the risks which we believecould occur due to incorrect work in a well-equippedworkshop, using work methods and tools tested byus.

In the workshop manual, all tasks for which there areVolvo Penta special tools, are done using these tools.

Special tools are specially prepared to permit the saf-est and most rational work methods possible. For thisreason, it is the responsibility of the person who usesother tools or other work methods than those recom-mended by us, to ensure that there is no risk of per-sonal injury or material damage, and that they can notcause any malfunctions.

In some cases, special safety regulations and user in-structions are available for the tools and chemicalsmentioned in the workshop manual. These rules mustalways be observed, so there are no special instruc-tions about this in the workshop manual.

The majority of risks can be prevented by taking cer-tain elementary precautions and using commonsense. A clean workplace and a clean engine elimi-nate many risks of both personal injury and malfunc-tion.

Above all, when work on fuel systems, lubricationsystems, inlet systems, turbocharger, bearing capsand seals is done, it is extremely important that nodirt or other kinds of foreign particles are able to getin, since this would otherwise cause malfunctions orshortened repair life.

Our common responsibility

Each engine consists of a large number of collaborat-ing systems and components. Any deviation of acomponent from its technical specification can dra-matically increase the environmental impact of an oth-erwise good engine. For this reason, it is extremelyimportant that specified wear tolerances are kept to,that systems with adjustment facilities are correctlyadjusted and that Volvo Penta Original Spares areused for the engine. The times noted in the enginemaintenance schedule must be observed.

Some systems, such as components in the fuel sys-tem, may require special competence and special testequipment. For environmental reasons etc., somecomponents are sealed at the factory. It is only per-missible to work on sealed components if you are au-thorized to do such work.

Remember that most chemical products damage theenvironment if they are incorrectly used. Volvo Pentarecommends the use of biodegradable degreaserswhenever engine components are de-greased, unlessotherwise specified in the workshop manual. Be care-ful to ensure that oils, wash residue etc. are proc-essed for destruction, and are not inadvertently dis-charged to the environment.

Tightening torque

The tightening torques for vital fasteners, whichshould be tightened with a torque wrench, are listed inTechnical Data, and are noted in the task descrip-tions in the manual. All torque specifications apply toclean screws, screw heads and mating faces. Thetorque specifications apply to lightly oiled or cleanscrews. If lubricants, locking fluids or sealants areneeded on a fastener, the type of preparation to beused will be noted in the job description and in Tight-ening Torques. Where a particular torque value is notspecified for any fastener, the general tightening tor-ques in the table below shall apply. The torque specifi-cation is a target value and the fastener does notneed to be tightened with a torque wrench.

Dimension Tightening torque

Nm lbf.ft.

M5 6 4.4

M6 10 7.4

M8 25 18.4

M10 50 36.9

M12 80 59.0

M14 140 103.3


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Torque-angle tightening

In torque/angle tightening, the fastener is tightened tothe specified torque, and tightening then continuesthrough a pre-determined angle. Example: for 90 an-gle tightening, the fastener is turned a further 1/4 turnin one sequence, after the specified tightening torque

has been achieved.

Lock nuts

Disassembled locknuts shall not be re-used, theyshall be replaced by new ones, since the locking prop-erties are impaired or lost when the nut is used sever-al times. On locknuts with plastic inserts, such as Ny-lock, the tightening torque specified in the tablemust be reduced if the Nylock nut has the same nutheight as a standard fully metallic hexagonal nut. Re-

duce the tightening torque by 25% if the screw dimen-sion is 8 mm (0.3") or greater. On Nylock nuts withhigher nut height, where the fully metallic thread is ashigh as on a standard hexagonal nut, use the tighten-ing torques in the table.

Strength classes

Screws and nuts are sub-divided into differentstrength classes. The classification is shown by amarking on the screw head. Markings of a higher

number indicate stronger material. For example, ascrew marked 10-9 is stronger than one marked 8-8.For this reason, it is important when fasteners are dis-mantled, that the screws are put back in the correctplaces when they are re-installed. When you changescrews, please check the spare parts catalogue to en-sure that the correct versions are obtained.

Sealants

Several different types of sealant and locking fluidsare used on the engine. The properties of the sealantsdiffer, and they are intended for different strengths offastener, temperature, resistance to oil and otherchemicals, and for the different materials and gap

thicknesses found in the engine.It is therefore important that the correct types of seal-ant and locking fluids are used on the fasteners whereneeded, to give a fully acceptable service result.

In the workshop manual, the relevant chapters containnotes on the preparations used in our engine produc-tion.

In service work, equivalent preparations of the samemake, or other makes of preparations with directlycorresponding properties shall be used.

When sealants and locking fluids are used, it is impor-

tant that the surfaces are free from oil, grease, paint,rust-protection and remains of old sealants. Alwaysobserve the manufacturers instructions about temper-atures of use, hardening times and other instructionsfor use of the product.

Two basic types of preparation are used on the en-gine, characteristics are as follows:

1. RTV preparations (Room Temperature Vulcanizing).These are mostly used together with gaskets, such asfor sealing gasket joints, or are brushed on gaskets.RTV preparations are fully visible when the compo-nent has been disassembled; old RTV compound

must be removed before the joint is sealed again.

The following preparations are RTV types: Loctite574, Volvo Penta 840879-1, Permatex No. 3, VolvoPenta 1161099-5, Permatex No 77. Remove oldsealant with denatured alcohol in each case.

2. Anaerobic preparations. These preparations hardenin the absence of air. These preparations are usedwhen two solid components, such as two cast compo-nents, are fitted together without a gasket. Commonuses are also to lock and seal plugs, stud threads,taps, oil pressure monitors etc. Hardened anaerobic

preparations are glassy and for this reason, the prepa-rations are colored to make them visible. Hardenedanaerobic preparations are highly resistant to sol-vents, and old compound can not be removed. On re-installation, degrease carefully and then apply newsealant.

The following preparations are anaerobic: Loctite 572 (white), Loctite 241 (blue).

Note. Loctite is a registered trademark of the Loctite Corpora-

tion.

Permatex is a registered trademark of the Permatex Corpora-tion.


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Group 23 EDC 4 General

Engine signs

Location of engine signs

The engines are supplied with two engine signs, ofwhich one is installed on the right side of the engineblock.

Engine plate

1. Engine model2. Engine specification number3. Engine series number (10 digits)4. Engine power, peak, without fan5. Engine speed6. Injection advance and type of camshaft7. Manufacturers identification code

8. Indication of standard and/or specification9. ISO 3046 , Air temperature in C (F)

10. ISO 3046, Altitude above mean sea level in me-ters

11. Unit injector code (EP code)12. Piston class13. Extra information


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Group 23 EDC 4 Tools

Special tools

Tools Designation use999 9324 Cable terminal pliers, repair

951 0060 Multimeter, fault tracing/checking

885675 Adapter (not illustrated)

999 9324 951 0060 951 2636

The following special tools are used in work on engines. Special tools can be ordered from Volvo Penta under thepart numbers given below.

999 8482 3838619

999 8482 Template, connector951 2636 Pin tool, connector

1078054 Repair kit (not illustrated)

3838619 VODIA

Other special equipment

AMP 726 519

AMP 825 514 AMP 825 582AMP 725 938

AMP 726 534HDT-48-00 0411-310-1605

The tools below are intended for use in work on the cable harnesses of the engine. The tools are not included inVolvo Pentas range, they must be ordered from a local AMPor Deutschdealer. If you experience problems incontacting a dealer, please contact Volvo Penta Quality Action Center for advice.

Deutsch connectors

HDT-48-00 Terminal crimping pliers

0411-310-1605 Dissasembly tool

JPT connector (25-pin EDC 4)

726 534-1 Dissasembly tool 1.6 mm pin width

726 519-1 Dissasembly tool 2.8 mm pin width

825 514-1 Terminal crimping pliers

Blades and sockets 3.5 mm

725 938-0 Dissasembly tool


4.8 mm and 6.3 mm cable clamps. Tongues andsocket terminals


AMP Connector (25-pin round)

872 070-1 Dissasembly tool (not illustrated)

734 289-2 Terminal crimping pliers (not illustrated)


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Group 23 EDC 4 Technical data

Technical data

Control unit

Voltage .................................................................. 24 V or 12 V (engine can be started from 6 V)

Connector .............................................................. 2 x 25-pin (AMP)

Max cable length .................................................... 5 m (16,4 ft)Working range, temperature ................................... -40 C (-40.0F) to +85 C (185.0F)

Current drain (incl. actuator) ...................................


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Coolant temperature sensor

Connector .............................................................. 2 pin

Working range, temperature ................................... -40 C (-40.0F) to +140 C (284.0F)

Rated voltage ......................................................... 5 0.15 VDC

Characteristic .......................................................... -40 C (-40.0F) 45313

0 C (32.0F) 589623 C (73.4F) 2057

60 C (140.0F) 596

100 C (212.0F) 186

140 C (284.0F) 71

Type ...................................................................... NTC* (Negative Temperature Coefficient)

Max. tightening torque ............................................ 20 - 24 Nm (14.7-17.7 lbf-ft)

Charge pressure sensor, 3 pin

Voltage ..................................................................5 V 0.25 VDC

Connector .............................................................. 3 pinWorking range, pressure: ....................................... 50 - 400 kPa (7-58.0 psi)

Pressure signal ...................................................... 0.5 4.5 VDC

Type ...................................................................... Linear

Max. tightening torque ............................................ 18 Nm (13.2 lbf-ft)

Charge pressure sensor, 4 pin

Voltage ..................................................................5 VDC

Connector .............................................................. 4 pin

Working range, pressure: ....................................... 40 -400 kPa (6-58.0 psi)

Pressure signal ...................................................... 0.3 -4.8 VDCType ...................................................................... Linear

Max. tightening torque ............................................ 3.3 Nm (2.4 lbf-ft)

* The resistance falls as the temperature rises.


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Oil pressure sensor

Voltage .................................................................. 5 V 0.25 VDC

Connector .............................................................. 3 pin

Working range, pressure: ....................................... 0 -1000 kPa (0-145.0 psi)

Pressure signal ...................................................... 0.5 -4.5 VDC

Type ...................................................................... Linear

Max. tightening torque ............................................ 45 Nm (33.1 lbf-ft)

Fuel temperature sensor

Connector .............................................................. 2 pin

Working range, temperature ................................... -40 C (-40.0F) to +140 C (284.0F)

Rated voltage ......................................................... 5 0.15 VDC

Characteristic........................................................ -40 C (-40.0F) 45313

0 C (32.0F) 5896

23 C (73.4F) 2057

60 C (140.0F) 596

100 C (212.0F) 186

140 C (284.0F) 71

Type ...................................................................... NTC* (Negative Temperature Coefficient)

Max. tightening torque ............................................ 20 -24 Nm (14.7-17.7 lbf-ft)

Air pre-heating (option)

Power .................................................................... 3600 W (24 V), 2000 W (12 V)

* The resistance falls as the temperature rises.


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Group 23 EDC 4 Design and function

Design and functionSystem description, EDC 4

EDC 4 (Electronic Diesel Control) and is an electronic system with CAN control (Controller Area Network) for die-sel engines. The system includes fuel management and diagnostic functions.

All engines can be controlled via CAN, with a potentiometer, or both. The accelerator control required can be setby using the VODIA tool (including Penta EDC4 software), please refer to the Parameter Setting chapter.

Summary

The system includes sensors, control unit and an en-gine speed regulator. The sensors send input signalsto the control unit, which controls the control rod forthe injection pumps in its turn, by means of an actua-

tor in the engine speed regulator.

Input signals

The control unit receives input signals about engineoperating conditions from the following components:

speed sensor, camshaft

coolant temperature sensor

charge pressure sensor

oil pressure sensor

fuel temperature sensor

coolant level sensor (the function is implementedin the control unit as standard, but no sensor issupplied with the engine)

Output signals

The control unit controls the following components onthe basis of the input signals received:

engine speed regulator (with position sensor forthe control rod and acutator)

electric air pre-heating (option)

Information from the sensors provides exact informa-

tion about current operation conditions and allows theprocessor to calculate the correct fuel volume, checkengine status etc.

Diagnostic function

The task of the diagnostic function is to discover andlocalize any malfunctions in the EDC 4 system, toprotect the engine and to ensure operation in the eventof serious malfunctions.

If a malfunction is discovered, this is notified by thediagnostic function, by warning lamps or via the CANnetwork. By pressing the diagnostic switch, the opera-tor will receive a fault code as a guide for any fault-tracing. Fault codes can also be output via the CANinterface or with Volvos VODIA tool (including thePenta EDC4 software) at an authorized Volvo Pentaworkshop.

If there is a serious malfunction, the engine is shutdown altogether. Yet again, fault codes can be outputvia diagnostic connector, the CAN interface or withVolvos VODIA tool (including the Penta EDC4 soft-ware) at an authorized Volvo Penta workshop.


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Other functions

The EDC4 system contains a number of functionswhose functions include engine protection.

Droop

Droop is the difference in engine speed between a fullyloaded and unloaded engine.

It is possible to switch between two different droopvalues while the engine is running.

The droop value can be changed between 0%(isochronous mode) and 5% (default).

If the droop connector is not connected, the engineruns in isochronous mode (0% droop).

The VODIA tool can be used to change the droop val-ue so that the value can be switched between 0% anda value between 0 10%

Stability

The engine speed regulator can be adjusted by meansof the VODIA tool, to trim the engine for a number ofdifferent applications. Please refer to the Fine adjust-ment, engine speed regulator chapter.

Fine adjustment, engine speed

Engine speed can be adjusted 8% up and down onsingle 1500 rpm or single 1800 rpm GE engines.

Single 1500 rpm GE: 1380 rpm - 1620 rpm Single 1800 rpm GE: 1656 rpm - 1944 rpmThis facility is not found on dual speed GE engines.

Smoke limiting

The control unit has an electronic smoke limitingfunction. This function monitors the charge airpressure and adjusts the fuel volume to avoidsmoke problems during acceleration (only appliesto VE engines).

Compensation, fuel temperature

The control unit regulates the fuel volume to givethe engines the same output power, irrespective offuel temperature.

Limp homeIf there is any fault in the signal from the accelera-tor pedal, the engine speed is set to 1200 rpm (so-called limp home speed).

NOTE! Only applies to VE engines.

Idling

Idling speed can be adjusted on VE engines, usingthe VODIA tool. Default value is 700 rpm.

Altitude correction

An option for engines which operate at altitudesabove 1,000 m (3,000 foot) above sea level, is anatmospheric pressure sensor and altitude correc-tion function. This function limits the fuel volume inrelation to ambient air pressure. This is to preventsmoke, high exhaust temperature and to protectthe turbocharger from overspeeding. gastempera-turer och fr att skydda turboaggregatet mot ver-varvning.


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Cold starting

The control unit controls engine speed increase during acold start. The control unit limits the number of rpm thatengine speed can increase per second.

Example: For VE engines at -30C (-22.0F) , enginespeed can not increase by more than 100 rpm per sec-ond (units: r/min/s), please refer to the diagram below.

VE engines:When coolant temperature is between -30 C (-22.0F)and +10 C (50.0F) , the control unit increases enginespeed as in the diagram below.

GE engines:When coolant temperature is between -30 C (-22.0F)and 0 C (32.0F) , the control unit increases enginespeed as in the diagram below.


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Component description

The numbers after the headings refer to the Compo-nent location chapter.

Control unit (EDC 4)The control unit, which is externally located (not onthe engine), monitors and controls the actuator to givethe correct fuel volume. Regulation is mainly donewith the aid of the engine speed sensor, coolant tem-perature sensor and the control rod sensor located inthe actuator.

The EDC 4 system processor is encased in the con-trol module and is protected against moisture and vi-bration.

The processor receives continuous information about:

engine speed charge air pressure coolant temperature fuel temperature oil pressure coolant level (option)The information provides exact information about cur-rent operation conditions and allows the processor tocalculate the correct fuel volume, check engine sta-tus etc.

Speed sensor, camshaft (1)

The engine speed sensor is located on the flywheelhousing, on the right hand side of the engine.

The engine speed sensor for the camshaft is an induc-tive sensor. The sensor reads camshaft movementand sends information about engine speed to the con-trol unit.

Coolant temperature sensor, (3)The sensor is located at the rear of the cylinder head,above the actuator.

The sensor senses the engine coolant temperatureand sends the information to the control unit. The sen-sor consists of a non-linear resistor, whose resistanceis dependent on the temperature of the resistor body.The resistance falls as the temperature rises.


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4-pin charge pressure sensor

3-pin charge pressure sensor

Charge pressure sensor (4 and 5)

There are two different types of charge pressure sen-sor.

The engines are delivered with either a 4-pin or a 3-pincharge pressure sensor.

The 4-pin charge pressure sensor is located on the in-let manifold above the engine.

The 3-pin charge pressure sensor is located betweenthe actuator and the round connector for the controlunit on the right side of the engine.

The charge air pressure sensor measures absolute

pressure, which is the sum of charge pressure plusatmospheric pressure. The sensor provides a signalwhose resistance is proportional to the absolute airpressure. The sensor receives a 5 Volt reference volt-age from the control unit.

Oil pressure sensor (7)

Oil pressure is measured by a sensor located abovethe oil filter on the right side of the engine.

The sensor consists of a non-linear resistor, whose re-sistance is dependent on the temperature of the resis-tor body. The resistance falls with rising temperature.The pressure signal is a voltage which is proportionalto the pressure. The reference voltage for the sensoris 5 Volt.


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Fuel temperature sensor (6)

The sensor is located on the right hand side of the en-gine, beside the fuel return pipe union. The sensor isof the same type as the coolant temperature sensor.

Speed regulator / Actuator (2)The actuator is located above the flywheel, on theright hand side of the engine.

The actuator consists of a control solenoid which oper-ates the control rod for the injection pumps, and a con-trol rod sensor which measures the position of thecontrol rod.

A signal from the accelerator goes to the control unit,which sends a signal to the control solenoid, which op-erates the control rod in its turn. Information about thetrue position of the control rod is sent back to the con-trol unit via the control rod position sensor, which canthen fine-tune the amount of fuel injected.

If the current to the actuator is cut, the control rod isforced back by the return spring. Fuel injection thenceases and the engine stops.


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Alternator

The alternator is belt driven and is located at the frontof the engine.

The voltage regulator on the alternator is providedwith a sensor system. The sensor system comparesthe charge voltage across the alternator terminals, B+and B-, with the current voltage across the positiveand negative battery terminals. The voltage regulatorthen compensates for any voltage drop in the cablesbetween the alternator and the battery, by increasingthe charge voltage supplied by the alternator as nec-essary.

Starter motor

The starter motor is installed on the flywheel housing,on the left-hand side of the engine.

When engaged, a gear wheel is first slid axially alongthe starter motor rotor spindle, so that it engages onthe gear ring on the engine flywheel. The axial move-ment of the gear, and connection of the starter motor,are controlled by an actuator solenoid on the startermotor.

The starter motor solenoid is engaged via the starterrelay in its turn, which is activated when the starterkey is turned to position III or the start button is de-pressed.

Electric heat pre-heating

A module for air pre-heating is available as an option.

The EDC4 control module controls air pre-heating viathis module.


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Component location

1. Speed sensor, camshaft

2. Speed regulator / Actuator

3. Coolant temperature sensor

4. Charge pressure sensor, 3 pin*

5. Charge pressure sensor, 4 pin*

6. Connection to control unit

7. Fuel temperature sensor

8. Oil pressure sensor

* Only one type of sensor is used.


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Group 23 EDC 4 Limit values

Limit values

These functions are customer parameters and can be shut off completely.

NOTE! The diagnostic lamp flashes when the alarm limit is reached, even if the function is shut off.

Alarm limits:

Coolant temperature: Warning lamp, coolant temp. lights up Engine is stopped

Default value Volvo Penta 110 C (230.0F) 113 C (235.4F)(goes out at 109C (228.1F)) after 30 sec.

Coolant level:

The control unit does not check this function until 25 s after starting. When the control unit receives a low coolantlevel signal, the engine is shut off after 5 sec.

Oil pressure:The control unit does not check this function until 30 s after starting.

The limit values depend on engine speed. The diagnostic lamp lights up when the limit value is reached, and goesout again when the oil pressure has risen 10% above the limit value. The engine is shut off when oil pressure fallsto 80% of the limit value.

Warning lamp, oil pressure, lights up Engine is stopped

Examples of default values: 800 rpm: 0.9 bar (13.0 psi) 0.72 bar (10.4 psi)(goes out at 1 bar (14.5 psi))

2000 rpm: 2.5 bar (36.2 psi) 2 bar (29.0 psi)(goes out at 2.75 bar (39.8 psi))


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Group 23 EDC 4 Parameter setting

22

Parameter setting

Adjustable parameters

The VODIA tool can be used to read and adjust theparameters below, in Parameter Programming mode:Please refer to the VODIA Users Guide for adviceon use.

NOTE! Special authorization is needed to be able toadjust certain parameters.

Full throttle voltage

Voltage at the throttle control input which correspondsto full throttle.

Min. value 0 V

Default value 4.6 V

Max. value 5 V

Maximum speed voltage error

A fault code is set if the maximum value is exceeded.

Min. value 0 V

Default value 4.9 V

Max. value 5 V

Idle voltage

Voltage at the throttle control input which correspondsto idling.

Min. value 0 V

Default value 0.3 V

Max. value 5 V

Idling speed voltage error

A fault code is set if the signal falls below the mini-mum value.

Min. value 0 V

Default value 0.1 V

Max. value 5 V

Idling speed.

Setting idling speed

Min. value 0 r/min

Default value 700 r/min

Max. value 4000 r/min


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PID regulator P section

P section which is used to control engine speed

Min. value 0 %

Default value VE: 10 %, GE: 30 %

Max. value 100 %

PID regulator I section

I section which is used to control engine speed

Min. value 0 %


Max. value 100 %

PID regulator D section

D section which is used to control engine speed

Min. value 0 %


Max. value 100 %

Droop

Selects the amount of droop to be used.

Min. value 0 %

Default value 5 %

Max. value 100 %

Accelerator control type(special authorizationneeded)

Selects the type of accelerator control to be used.

Alternative modes:

None

Potentiometer

CAN

Both

CAN communication (special authorization needed)

CAN communication on or off.

Alternative modes Off or On

Default value: VE engines: On

GE engines Off

Coolant temperature protection(Special authorization needed)

Chooses whether engine protection should be activatedin relation to high coolant temperature.

Alternative positions Off or On

Default value: On

If On, the coolant temperature warning lamp lights upat 110 C (230.0F) (goes out at 109C (228.1F))

The engine is shut off at 113 C (235.4F) after 30 sec.

Coolant level protection

(special authorization needed)

Chooses whether engine protection should be activatedin relation to low coolant level.


Default value: On

If On, the control unit does not check this functionuntil 25 s after starting. When the control unit receivesa low coolant level signal, the engine is shut off after 5sec.

Oil level protection(special authorization needed)

Chooses whether engine protection should be activatedin relation to low oil pressure.


Default value: OnIf On, the control unit does not check this functionuntil 30 s after starting.

The limit values depend on engine speed. The oil pres-sure warning lamp lights up when the limit value isreached, and goes out again when the oil pressure hasrisen 10% above the limit value. The engine is shut offwhen oil pressure falls to 80% of the limit value.

Examples of default values:

800 rpm - the oil pressure warning lamp lights up at 0.9bar (13.0 psi) (goes out at 1 bar (14.5 psi) ) and the en-

gine is shut off at 0.72 bar (10.4 psi) .2000 rpm - the oil pressure warning lamp lights up at2.5 bar (36.2 psi) (goes out at 2.75 bar (39.8 psi) ) andthe engine is shut off at 2 bar (29.0 psi) .

Control rod(Special authorization needed)Control rod calibration.

Min. value 0 mm (0)

Max. value 20 mm (0.7874")


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Read-only parameters

The VODIA tool can be used to read and the valuesbelow, in Log test mode: Please refer to the VODIAUsers Guide for advice on use.

Battery voltage

Coolant temperature

Charge air pressure

Oil pressure

Fuel temperature

Engine speed

Accelerator linkage %

Droop %

Accelerator position voltage (Only in ParameterProgramming mode in the VODIA tool).

Engine total running time

Engine loading %

Fine adjustment, engine speedregulator

Each control unit supplied with the engine or as aspare part has a default setting. The default setting ischosen to allow the engine to work in most applica-tions.

In certain circumstances, the engine can run unevenlyor behave in an undesirable manner. If this is thecase, the engine should be checked in the order andusing the procedures below:

1. Check whether the control unit has set a faultcode and rectify this if necessary, in accordancewith the Diagnostic functions and Fault codeschapters.

2. Check and attend to possible symptoms in ac-cordance with the Fault tracing chapter.

3. Check and adjust the engine speed regulator as

below.

Use the VODIA tool (including Penta EDC4 software),to read and adjust the P, I and D sections of the en-gine speed regulator. In some cases, this can offermore stable and more even engine running.

PID = Proportional, Integrating, Differential

The P sectionamplifies (Gain). A reduced value(Fig. 1)gives slower regulator reaction to load chang-es. An increased value (Fig. 2)gives faster reaction.

The I sectionstabilizes (Stability). A reduced value(Fig. 3)

increases the time taken by the system to recover af-ter a load change. An increased value (Fig 4) gives ashorter recovery time.

The D sectionstabilizes (Differential). Reacts to themagnitude of the engine speed change. A reducedvalue(Fig 4) gives reduced sensitivity. An increasedvalue (Fig. 5)gives increased stability.

Before any adjustments are made, the current valuesof the P, I and D sections of the PID regulator shouldbe noted.

NOTE! Without the default values, the engine speedregulator / actuator can not be restored if adjustmentis not successful.

Please refer to the VODIA Users Guide for adviceon use.


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Adjustment

1. Use the VODIA tool and note the current values ofthe P, I and D sections of the PID regulator.

2. Start the engine.

3. Run the engine at working speed without load, andfirst increase the value of the P section of the PID

regulator until unstable (oscillating) engine speedis achieved. Then reduce the parameter by 1-2%until the engine speed is stable again.

4. Then adjust the I section of the PID regulator inthe same way as above.

5. If the engine still runs badly and no other adjust-ments help, increase the D section of the PIDregulator until the engine only has a very small in-crease in speed when load is applied or removed,please refer to fig. 6.

NOTE! The few times that the D section may

need to be adjusted include cases where the ap-plication has a flexible coupling or extremely lowflywheel inertia.

6. Adjust the P and I sections again as above, ifnecessary.

7. Check engine response as fig. 6.

Fig 4. I section too high or D section too low

Verkligt varvtal

Demanded engine speed

True engine speed

time

rpm

Fig 3. I section too low


True engine speed

time

rpm

Fig 1. P section too low


True engine speed

time

rpm

Fig 2. P section too high

True engine speed


time

rpm

Fig 5. D section too high


True engine speed

time

rpm

Fig 6. Demanded response

Load removal

Load application

time

rpm



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Repair instructions

Working on the EDC4 system

Follow the instructions below, to avoid damage to the EDC4 system control unit.

Never turn off the main switch when the engine is running.

Never undo the battery cables when the engine is running.

When the batteries are quick charged, turn the main switch off or undo the battery cables.During normal maintenance charging, the main switch does not need to be turned off.

Only batteries may be used for start help. Quick starting units can give excess voltages and damage the con-trol module.

Disconnect the EDC4 system from system voltage before undoing either of the 25 pin connectors on the con-trol unit.

If you discover any damage on the cable harnesses, undo the connector on the control unit.IMPORTANT! Always undo the connectors on the control unit before doing any welding.

When a connector is undone from a sensor, be careful to ensure that the connector pins are not exposed tooil or other fluids. The consequence of this can be contact problems, or if oil runs down onto the pressuresensing diaphragm, the sensor will indicate an incorrect value.


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Control unit, change

Each control unit is tied to a specific engine via theengine serial number. This means that it is not possi-ble to transfer a control unit from one engine to anoth-er.

If a control unit is changed, the new control unit must

have that particular engines:

data setup (firmware)

engine number.

1. Disconnect system voltage from the engine.

2. Disconnect the cable connectors from the controlunit.

3. Install the new control unit.

4. Connect the cable connectors to the control unit.

NOTE! The control unit must not be installed on theengine.

Speed regulator, changeTo change the engine speed regulator, please refer tothe workshop manuals for each mechanical engine(not EDC).

Please refer to the workshop manual, Industrialengines TD420VE, TAD420VE, TD520GE,TAD520GE, TD520VE TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE TAD660VE,TD720GE TAD720GE, TD720VE, TAD720VETAD721GE, TAD721VE, TAD722GE, TAD722VE,TAD730/731/732/733GE, TAD750VE, TAD760VE.


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Starting with auxiliary

batteries

WARNING! Ventilate well. Batteries generate anexplosive gas which is highly flammable and ex-plosive. A short circuit, open flame or spark

could cause an explosion.

WARNING! Never switch over the battery cablepositions on the battery. Switching the batteryterminals over when using jumper cables forstart help causes short circuits and arcing,which could cause an explosion and cause con-siderable damage to electrical components onthe engine.

1. Check that the voltage of the help start battery isthe same as the system voltage of the engine.

2. First connect the red (+) jumper cable to the posi-tive (+) poleon the flat battery, then to the posi-tive (+) poleon the auxiliary battery.

3. Then connect the black jumper cable to the nega-tive pole ()of the help start battery, and to aplace some distance from the flat battery, suchas the negative connection on the starter motor.

WARNING! Under no circumstancesmay theblack jumper cable () come into contact withthe positive cable connection on the starter mo-tor.

4. Start the engine and run at a fast idle for about 10minutes to charge the batteries.

WARNING! Working with, or going close to arunning engine is a safety risk.Watch out for rotating components and hot sur-faces. Do not touch the connections during thestart attempt. Risk of arcing. Do not stand bentover any of the batteries either.

5. Switch off the engine.Remove the jumper cables in the exactreverseorder from installation. One cable at a time!


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Group 23 EDC 4 Function check

Function check

Diagnostic function for VODIA (including Penta EDC 4 software)

The program can read fault codes which have been stored in the engine control unit, check input and output

signals, read off current values from engine sensors, and then store and print out test results.

The program allows service and workshop personnel to quickly localize and attend to faults in the EDC4 sys-tem.

It is connected to the engine control unit via a diagnostic connector (VODIA input), please refer to the Wiringschedule chapter.

User information is included with the program. Please contact your Volvo Penta dealer to order the software. The task of the diagnostic function is to discover and localize any malfunctions in the EDC 4 system, to pro-

tect the engine and to ensure operation in the event of serious malfunctions.

If a malfunction is found, the diagnostic indicator in the control panel begins to flash. A diagnostic trouble

code (DTC) can be obtained by pressing the diagnostic button, as a guide for any fault-tracing.

Please refer to the VODIA Users Guide for more information and advice on use.


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Group 23 EDC 4 Function check

Fault tracing

A number of symptoms and possible causes of engine malfunctions are described in the table below. Always con-tact your Volvo Penta dealer if any problems occur which you can not solve by yourself.

WARNING! Read through the safety advice for care and maintenance work in the Safety information chap-ter before starting work.

Symptoms and possible causes

The diagnosis button lamp flashes. Please refer to theDiagnostic information chapter.

Engine can not be stopped. 2, 4

Starter motor does not rotate 1, 2, 3, 4, 5, 6, 7, 24

Starter motor rotates slowly 1, 2

Starter motor rotates normally but engine does not start 8, 9, 10, 11

Engine starts but stops again 8, 9, 10, 11, 13

Engine does not reach correct operating speed at full throttle 9, 10, 11, 12, 13, 21, 25, 26

Engine runs roughly 10, 11, 27

High fuel consumption 12, 13, 15, 25

Black exhaust smoke 12, 13

Blue or white exhaust smoke 14, 15, 22

Too low lubrication oil pressure 16

Excessive coolant temperature 17, 18, 19, 20

Too low coolant temperature 20

No, or poor charge 2, 23

1. Flat batteries

2. Poor contact/open circuit incables

3. Main switch turned off

4. Faulty ignition lock

5. Faulty main relay

6. Faulty starter motor relay

7. Faulty starter motor/solenoid

8. Lack of fuel:- fuel taps closed- fuel tank empty/wrong tank connected

9. Blocked fuel filter/pre-filter(because of contamination, orparaffin fraction separation in

fuel at low temperature).10. Air in the fuel system

11. Water/contamination in fuel

12. Faulty injection pumps

13. Insufficient air supply to engine:- blocked air filter- air leakage between turbo charger and engine inlet pipe.

- fouled compressor section in turbocharger- faulty turbocharger- poor engine bay ventilation

14. Excessive coolant temperature

15. Too low coolant temperature

16. Too low oil level

17. Coolant level too low

18. Air in the coolant system

19. Faulty circulation pump20. Defective thermostat

21. Blocked intercooler

22. Too high oil level

23. Alternator drive belt slips

24. Water entry into engine

25. High back pressure in

exhaust system

26. Break in Pot+ cable topedal

27. Incorrectly set enginespeed regulator / actuator(PID regulator)


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Group 23 EDC 4 Diagnostic function

Diagnostic function

The diagnostic function monitors and checks that theEDC 4 system functions normally.

Diagnostic function, tasksThe diagnostic function has the following tasks: Discover and localize malfunctions.

Notify that malfunctions have been discovered.

Give advice in fault finding.

Protect the engine and ensure continued operationwhen serious malfunctions are discovered.

Malfunction message

If the diagnostic function discovers a malfunction inthe EDC 4 system, this is notified via the CAN bus orthe diagnostic lamp lights up or starts to flash. At thesame time, the fault is stored in the control unit mem-ory. As soon as the fault has been attended to and theignition is turned off and on, the fault code lamp goesout. Both rectified (passive) and un-rectified (active)faults are stored in the control unit and can be read byan authorized workshop.

Fault tracing guide

If the diagnostic switch is depressed (for 1-3 seconds)

and then released, a fault code is flashed out from thediagnostic lamp. The fault code is found in the faultcode list, with information about the reason, reactionand measures to be taken. Please refer to the Faultcodes chapter.

Effect on engineThe diagnostic function affects the engine in the fol-lowing ways:

1. The diagnostic function has discovered a minormalfunction which does not damage the engine.

Reaction: The engine is not affected. The diag-nostic lamp lights up.

2. The diagnostic function has discovered a seriousmalfunction which makes it impossible to controlthe engine.

Reaction: The diagnostic lamp starts to flash. En-gine is shut off.

Operation

During starting

When the ignition is turned on, the diagnostic lamplights up for two seconds, together with the warninglamps for oil pressure and coolant. This is to checkthe lamp function.

If the diagnostic lamp flashes after the two seconds,

this indicates a serious fault and the engine can notbe started. One or more fault codes can then beflashed out.

If the diagnostic lamp is lit, there are one or more lessserious faults. One or more fault codes can then beflashed out.


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Group 23 EDC 4 Diagnostic function

During operation

If the diagnostic lamp starts to flash during operation:

1. Reduce engine speed to idling.2. Press the diagnostic button (for 1-3 seconds).

3. Release the diagnostic button and make a note ofthe diagnostic trouble code (DTC) that is flashedout. Please refer to Reading fault codes below.

4. Look up the fault code in the fault code list andtake the necessary measures. Please refer to theFault codes chapter.

If the diagnostic lamp starts to flash, the engine willbe emergency stopped.

IMPORTANT! In VE engines, there is a functionin the system which makes it possible to startthe engine again and run it for about 25 sec-onds. This is so that the vehicle can be movedfrom a railway level crossing etc.

Reading fault codes

Fault codes can either be read via:

The VODIA tool (including the Penta EDC4 soft-ware). Please refer to the VODIA Users Guidefor advice on use.

Diagnostic lamp

CAN

Diagnostic lamp

If the diagnostic lamp is illuminated or flashes, a faultcode can be read by pressing the diagnostic button(for 1-3 seconds) and then releasing it. The diagnosticlamp goes out, and a fault code is then flashed out.

The fault code consists of three groups of flashes,separated by a pause of two seconds.

The first and third group consist of short flashes (0.4s). The second group consists of long flashes (0.8 s).

A fault code is obtained by counting the number offlashes in each group.

Example: (2 short) pause (2 long) pause(1 short) = Fault code 2.2.1

The fault code is stored and can be read as long asthe fault remains. You can find information aboutcause, reaction and actions in the fault code list.Please refer to the Fault codes chapter.

Read as follows:

1. Press the diagnostic button (for 1-3 seconds).

2. Release the diagnostic button and make a note ofthe fault that is flashed out.

3. Repeat items 1-2. A new fault code is flashed outif more are stored. Repeat until the first fault codeis repeated.

NOTE! When the first fault code is repeated, all faultcodes have been read out.

When all faults have been rectified:

1. Turn the ignition on and off.

2. Press the diagnostic button (for 1-3 seconds) tocheck whether any faults remain.

3. If there are no active faults, the diagnostic lampwill give two short flashes, in other cases the re-maining non-rectified faults will be flashed outagain.


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Group 23 EDC 4 Fault codes

Fault codes

WARNING! Read through the safety advice for care and maintenance work in the Safety information chap-ter before starting work.

Code 2.0.0 No faults

There are no active faults.

PID 190, Code 2.1.1 Engine speed sensor,camshaft

Reason: Faulty sensor, connector, cables or incorrect dis-tance to cam wheel. High frequency interference.

Reaction: Engine is shut off.

Action:

Check that the engine speed sensor is installedwith the correct distance to the camshaft.

Check the cables for the engine speed sensor forbreaks and short circuits.

Check the connector for poor contact.

Check engine speed sensor function. Change thesensor as necessary.

PID 190, Code 2.1.4 Overspeed

Reason: The engine speed is or has been higher than thepermissible limit.

Reaction: Fuel injection ceases and the fault code lamplights up until the engine speed falls below the permissiblelimit again.

Action:

Check the control rod for the injection pumps,please refer to workshop manual Industrial enginesTD420VE, TAD420VE, TD520GE, TAD520GE,TD520VE TAD520VE, TAD530/531/532GE,TAD620VE, TAD650VE TAD660VE, TD720GETAD720GE, TD720VE, TAD720VE TAD721GE,TAD721VE, TAD722GE, TAD722VE, TAD730/731/732/733GE, TAD750VE, TAD760VE.

Check the actuator, replace it if necessary, pleaserefer to chapterFault tracing of engine speed regulator or Enginespeed regulator, change.

Check the cables for the actuator for breaks andshort circuits.

Check the number of teeth on the camshaft wheel.

For VE engines, it may be necessary to check thefunction of the limp home mode

PID 91, Code 2.2.1 Accelerator pedal sensor

Reason: Faulty sensor, connector or cable.

Reaction: The engine goes into limp home mode.

Action:

Check the sensor cable for breaks and short cir-cuits.

Check sensor function. Change the sensor as nec-essary.


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PID 174, Code 2.2.7 Fuel temperature sensor


Reaction: A fault code is generated.

Action:

Check the sensor cable for breaks and short cir-

cuits.

Check the sensor function, please refer to theElectrical fault tracing chapter. Change the sen-sor as necessary.

PID 100, Code 2.3.1 Warning, oil pressure

Reason: Oil pressure below specified limit value (de-pends on engine speed).

Reaction: A fault code is generated. The fault code disap-pears when the oil pressure exceeds the recuperation val-

ue.Action:

Check the oil level and oil pump.



Check the limit value for oil pressure warning,please refer to the Limit values chapter.

PID 110, Code 2.3.2 Warning, coolant temperature

Reason: Excessive coolant temperature

Reaction: A fault code is generated. The fault code disap-pears when the coolant temperature falls below the recu-peration value.

Action:

Check the coolant.



PID 102, Code 2.2.3 Charge pressure sensor



Action:

Check the sensor cable for breaks and short cir-

cuits.


PID 100, Code 2.2.4 Oil pressure sensor



Action:



PID 110, Code 2.2.5 Temperature sensor, coolant



Action:




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PID 174, Code 2.3.7 Warning, fuel temperature

Reason: Excessive fuel temperature.

Reaction: A fault code is generated. The fault code disap-pears when the fuel temperature falls below the recupera-tion value.

Action:

Check the fuel.



PID 100, Code 2.3.1 Emergency stop, oil pressure

Reason: Oil pressure below specified limit value.

Reaction: Engine is emergency stopped.

Action:

Check the oil level and oil pump.



Check the limit value for engine shut-off due to oilpressure.

PID 110, Code 2.3.2 Emergency stop, coolanttemperature

Reason: Excessive coolant temperature

Reaction: Engine is emergency stopped.

Action:

Check the coolant.



Check the limit value for engine shut-off due tocoolant pressure.

PID 111, Code 2.3.5 Warning, coolant level

Reason: Coolant level too low


Action:

Check the coolant level.


Check sensor function (if installed).

Change the sensor as necessary.

NOTE! The engine is supplied without a coolant level sen-sor.

PID 190, Code 2.3.6 Overspeed in limp homemode

Reason: When the limp home mode is activated and theengine speed is or has been higher than the permissiblelimit value.

Reaction: GE: Engine is shut off. A fault code is generat-ed.

VE: Fuel injection ceases when the control rod returns toits home position and the fault code lamp lights up untilthe engine speed falls below the permissible limit again.

Action:

Check the control rod for the injection pumps,please refer to workshop manual Industrial en-gines TD420VE, TAD420VE, TD520GE,

TAD520GE, TD520VE TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE TAD660VE,TD720GE TAD720GE, TD720VE, TAD720VETAD721GE, TAD721VE, TAD722GE, TAD722VE,TAD730/731/732/733GE, TAD750VE, TAD760VE.

Check the actuator, replace it if necessary, pleaserefer to chapter

Fault tracing of engine speed regulator or En-gine speed regulator, change.


Check the number of teeth on the camshaftwheel.

For VE engines, it may be necessary to check thefunction of the limp home mode


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PID 111, Code 2.3.5 Emergency stop, coolantlevel

Reason: Low coolant level

Reaction: The engine is emergency stopped and can notbe re-started until the fault is rectified.

Action:

Check coolant level.


Check sensor function (if installed).Change the sensor as necessary.

NOTE! The engine is supplied without a coolant level sen-sor.

SID 24, Code 2.5.1 Control rod position sensor

Reason: Actuator not connected. Faulty value from controlrod position sensor in actuator.

Reaction: Engine is emergency stopped. Actuator can notbe controlled.

Action:

Check the actuator, replace it if necessary, pleaserefer to chapter Fault tracing of engine speedregulator or Engine speed regulator, change.


SID 24, Code 2.5.1 Control rod position sensor,reference

Reason: Actuator not connected. Faulty value from controlrod position sensor in actuator.

Reaction: Engine is emergency stopped. Actuator can notbe controlled.

Action:



SID 23, Code 2.5.1 Control rod position sensor,difference

Reason: Injection pump/actuator has got stuck or is notconnected. Difference between control rod current valueand nominal value exceeds 10%.

Reaction: A fault code is generated. The fault code disap-pears when the difference between control rod currentvalue and nominal value falls below 10%.

Action:

Check the control rod for the injection pumps,please refer to workshop manual Industrial en-gines TD420VE, TAD420VE, TD520GE,TAD520GE, TD520VE TAD520VE, TAD530/531/532GE, TAD620VE, TAD650VE TAD660VE,TD720GE TAD720GE, TD720VE, TAD720VETAD721GE, TAD721VE, TAD722GE, TAD722VE,TAD730/731/732/733GE, TAD750VE, TAD760VE.



SID 23, Code 2.5.2 Injection pump, autocalibration

Reason: Automatic actuator equalization is not possible.Faulty calibration.

Reaction: The engine is emergency stopped and can notbe re-started until the fault is rectified. The regulator cannot be activated.

Action:


Check the actuator cables.

Turn the ignition off and on, and check if the faultcode remains.

SID 231, Code 2.7.1 Communication fault, CANbus

Reason: CAN controller for CAN bus is faulty.

Reaction: --

Action:

Check the cables.

Check the control unit.


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SID 252, Code 2.8.1 Parameter programming

Reason: Memory fault


Action:


SID 240, Code 2.8.1 Cyclical program test

Reason: Memory fault


Action:


PID 158, Code 2.9.1 Control unit, voltage supply

Reason: Voltage supplied to actuator exceeds permissi-ble limit values.

Reaction: A fault code is generated. The fault code disap-pears when the voltage returns to within the permissiblelimit values.

Action:


PID 158, Code 2.8.2 Reference voltage 1

Reason: Reference voltage for actuator exceeds permis-sible limit values.

Reaction: A fault code is generated. The fault code disap-pears when the voltage returns to within the permissiblelimit values (5 V).

Action:

Check the voltage supplied.




Reaction: A fault code is generated. The fault code disap-pears when the voltage returns to within the permissiblelimit values (5 V).

Action:





Reaction: A fault code is generated. The fault code disap-pears when the voltage returns to within the permissible

limit values (5 V).

Action:




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PID 48, Code 2.9.2 Atmospheric pressure

Reason: Air pressure is outside permissible values.

Reaction: A fault code is generated. The fault code disap-pears when the pressure returns to normal. Monitoringfunction for air pressure is de-activated.

Action:


SID 253, Code 2.10.1 Parameter fault

Reason: No data or incorrect data (fault only occurs dur-ing parameter setting or reset).

Reaction: Engine can not be started.

Action:

Check parameter settings.


SID 240, Code 2.10.1 Stack overflow

Reason: Internal calculation fault.


Action:

Turn the ignition off and on, and check if the fault

code remains.


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Group 23 EDC 4 Electrical fault finding

Electrical fault finding

General

The following should be checked before electricalfault tracing starts:

Fault codes Fuel level and filter Coolant level Air filter Battery Cables (visual) Main switch, circuit breakers, connectors Relay connections

Electric fault finding can be done on the followingcomponents:

Actuator Engine speed sensor Coolant temperature sensor Charge air/charge air sensor. Oil pressure sensor Fuel temperature sensor

Starter motor Alternator

Function checking of cables

and connectors

First check that none of the circuit breakers hastripped.

Use multimeter 9510060 to measure the cables.

Connect adapter 885675 between the engine cableconnector and the control unit.

Check the wiring schedule to ensure that measure-ment is done at the correct place.

Use multimeter 9510060 to measure the cables.

NOTE! Never do measurements by poking a probethrough insulation.

Check all measurements against the data read fromthe wiring schedule.

If a measurement value can not be interpreted fromthe wiring diagram, check the wires separately.

Contact problems

Intermittent contact or temporary recurring faults canbe difficult to fault trace, and are frequently caused byoxidation, vibration or poorly terminated cables.

Wear can also cause faults. For this reason, avoiddisconnecting a connector unless it is necessary.

Other contact problems can be caused by damage topins, sockets and connectors etc.

Shake cables and pull connectors during measure-ment, to find where the cable is damaged.

Resistance in connectors, cables and junctionsshould be 0 Ohm.

A certain amount of resistance will occur, however,because of oxidation in connectors.

If this resistance is too great, malfunctions occur. Theamount of resistance that can be tolerated before mal-functions occur varies, depending on the load in the

circuit.


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Check the following:

Look for oxidation which can impair contact in con-nectors.

Check that terminals are undamaged, that they arecorrectly inserted into their connectors, and thatthe cable is correctly terminated in the terminal.

Test whether the sockets give good mechanicalcontact. Use a loose pin for this test.Important! The engine management unit con-nector must only be checked by means of gauge9998482.

Carefully insert gauge 9998482 into the connec-tors. Pull the gauge back and forwards a fewtimes, and feel whether the connectors grip thegauge. If the connectors have lost their grip, or ifthey are weak, change the spade terminals.Please refer to the Joining electrical cables for

multi-connector chapter.

Fill sockets which have been checked with lowtemperature grease 1161417-9.

Important! Pressure sensorsmust not be filledwith grease.

Check that the cables are correctly clamped.Avoid clamping cables in a very tight radius be-side connectors.

Fault tracing of cables and

connectors

Do a visual check on connectors


Look for oxidation which can impair contact inconnectors.

Check that terminals are undamaged, that theyare correctly inserted into their connectors, and

that the cable is correctly terminated in the termi-nal.

Test whether the sockets give good mechanicalcontact. Use a loose pin for this test.

Shake cables if possible, and pull connectors dur-ing measurement, to find where the cable is dam-aged.

Open circuit

Chafed or torn cables and connectors which havecome loose can be possible fault causes.

Use the wiring schedule to check the cable harnesseswhich are relevant to the function. Start off with themost probable cable harness in the circuit.


Disconnect the relevant connector at each end ofthe cable harness.

Use multimeter 9510060-8 to measure the resist-ance between the ends of the cable. Nominal val-ue R ~ 0 .

Shake cables if possible, and pull connectors dur-ing measurement, to find where the cable is dam-aged.

If the fault can not be found, check the next cableharness as in the wiring schedule.

Contact resistance and oxidation

Resistance in connectors, cables and junctionsshould be 0 .

A certain amount of resistance will occur, however,because of oxidation in connectors.

If this resistance is too great, malfunctions occur. Theamount of resistance that can be tolerated before mal-functions occur varies, depending on the load in thecircuit.


Look for oxidation which can impair contact inconnectors.

Check that terminals are undamaged, that theyare correctly inserted into their connectors, andthat the cable is correctly terminated in the termi-nal.

Test whether the sockets give good mechanicalcontact. Use a loose pin for this test.

Important! Pressure sensorsmust not be filled

with grease.


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Joining electrical cables for

multi-connectors

Special tools: 951 2636, 9999324

Repair kit: 1078054

1. Remove the connectors from the control unit,please refer to Control unit, change. Disassem-ble the connector, to gain access to the cableleading to the pin which is to be changed.

2. Remove the pin, using tool no. 9512636 or a verysmall jewelers screwdriver.

NOTE! Only remove one pin at a time.

3. Cut off the cable and the pin which is to bechanged. Join the cable with the new one, usingrepair kit 1078054. Use cable crimping tool no.

9999324.

4. Carefully heat the joint with a hot air gun, to makethe insulation shrink and seal tightly.

5. Put the pin back in the right place in the connec-tor before removing the next pin, if several pinsare to be changed. Check that the locking tab onthe pin locks the pin into the connector.

6. Install the cables with insulation and tie wraps inthe connectors, in the reverse order to disassem-bly.

7. Install the connectors in reverse order to disas-sembly.

8. Make sure that the connector and the connectionon the control unit are clean and dry.

9. Connect the connectors to the control unit, pleaserefer to Control unit, change.

10. Start the engine and check carefully that no faultcodes occur.


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Inspection/fault tracing of components

Checking the sensor, charge pressure

NOTE! There are two different types of charge pres-sure sensors. A 3-pin and a 4-pin sensor.

1. Shut the engine off

2. Undo the connector on the charge air pressure

sensor and connect adapter no. 885675 betweenthe charge air pressure sensor connector and theengine cable harness. Then connect multimeter9510060-8 between measurement points 1-3 (ap-plies to both sensors).

3. Turn the control voltage on.

4. Measure, with the multimeter set to voltage meas-urement. Check that the multimeter indicates 5.0Volt.

5. Then con

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